Systems, apparatuses, and methods related to fiber strands used in reinforced concrete

ABSTRACT

A reinforcing bar, and a method of producing a reinforcing bar, are provided. The reinforcing bar includes a plurality of strands and a deformity pattern. Each strand includes a plurality of carbon fibers. The strands having been impregnated with a resin and twisted forming a unified structure. The deformity pattern being formed within the unified structure by twisting the strands a predetermined number of times per linear foot of the unified structure and allowing the resin-impregnated unified structure to cure.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationSer. No. 62/506,432, filed on May 15, 2017 and U.S. Provisional PatentApplication Ser. No. 62/571,920, filed on Oct. 13, 2017, the disclosuresof which are hereby incorporated by reference in their entirety and forall purposes.

TECHNICAL FIELD

The present invention is related to resin impregnated carbon fiber, andmore particularly, to systems, methods and apparatus related to the useand formation of a resin impregnated carbon fiber.

BACKGROUND OF THE INVENTION

Concrete is used in many different types of construction projects,including, but not limited to walls, retaining walls, bridges, roadways,building foundations, etc. . . . . Concrete is a composite material thatis composed of coarse aggregate bonded together with a fluid cement thathardens over time. Concrete may be poured off-site in forms to obtain aconcrete structure in a desired shape and then transported on-site to beinstalled or it may be poured on-site in field constructed forms.

It is known that most applications require one to reinforce concretecomponents using reinforcing members. In most cases, the reinforcingmembers are composed of corrosion susceptible steel, such as reinforcingbar or rebar. However, over time steel will degrade into iron oxidecommonly referred to as rust. This degradation will eventually diminishthe integrity of the rebar, and thus, the concrete structure. In manyapplications steel rebar may have a deformity, i.e., a deformed patternthat is designed to increase the friction between rebar and the materialin which it is embedded.

Recent attempts to overcome the shortcomings of steel rebar utilizereinforcing bars composed of carbon fibers. In general, carbon fiberbased rebar is comprised of a plurality of unidirectional glass fibersthat have been reinforced or thermoset with resin. The widely acceptedproperties of carbon fiber strands indicate that a member with a smallcross-section will perform quite well in tension, but very poorly inshear. This is a fact that was experimentally confirmed during testingof a carbon fiber rebar (CF) with parallel carbon fiber strands. It wasalso found that a CF sample wherein all fibers are parallel with nosurface deformations does not have sufficient bond strength with acementitious material. This fact has since been confirmed by theAmerican Concrete Institute (ACI) (440.6-3). The ACI goes as far as torequire suppliers of fiber reinforced polymer (FRP) to provide themethod by which the surface of the FRP is deformed.

The deformed pattern may be replicated by “pinching” of the fibers priorto being set by the resin. However, this does not overcome thedeficiencies of carbon fiber based rebar over steel rebar.

The present invention is aimed at one or more of the problems set forthabove.

SUMMARY OF THE INVENTION

In a first aspect of the present invention, a reinforcing bar isprovided. The reinforcing bar includes a plurality of strands and adeformity pattern. Each strand includes a plurality of carbon fibers.The strands having been impregnated with a resin and twisted forming aunified structure. The deformity pattern being formed within the unifiedstructure by twisting the strands a predetermined number of times perlinear foot of the unified structure and allowing the resin-impregnatedunified structure to cure.

In a second aspect of the present invention, a concrete structure isprovided. The concrete structure includes a concrete member and areinforcing bar. The concrete member is formed about the reinforcing barwhile the reinforcing bar is under stress. The reinforcing bar includesa plurality of strands. Each strand includes a plurality of carbonfibers. The strands have been impregnated with a resin and twistedforming a unified structure. A deformity pattern within the unifiedstructure is formed by twisting the strands a predetermined number oftimes per linear foot of the unified structure and allowing theresin-impregnated unified structure to cure.

In a third aspect of the present invention, a method is provided. Themethod includes the steps of dipping a plurality of strands of carbonfibers in a bath of resin, pulling the strands of carbon fibers throughan outgoing pair of rollers, as the strands leave the bath of resin, andtwisting the strands of carbon fibers together to form a desireddeformity pattern. The method further including the steps of allowingthe resin to cure to form a reinforcing bar.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are explanatory diagrams of parameters associated withan exemplary reinforcing rod associated with the present invention;

FIGS. 1C through 24C are diagrammatic illustrations of a reinforcingbar, rod or member and/or structures used in the production of areinforcing bar, rod or member, according to embodiments of the presentinvention;

FIGS. 25-31 are diagrammatic illustrations of systems for allowing(building) components to attach to a concrete member, according toembodiments of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

With reference to the drawings, and in operation, the present inventionis related to reinforcing bars and/or concrete structures withreinforcing bars. The reinforcing bars may be resin impregnated carbonfibers. In particular, the present invention may be related to systems,methods and apparatus, related to the formation and use of resinimpregnated carbon fibers and/or methods and structures to apply tensionor stress to reinforcing bars and/or methods or structures related tothe production of concrete structures.

In general, in one aspect of the present invention, a reinforcing barcomposed of carbon fiber strands is provided. In another aspect of thepresent invention, a system and method for producing reinforcing barcomposed of carbon fiber strands is provided. In still another aspect ofthe present invention, an apparatus for producing reinforcing barcomposed of carbon fiber strands is provided. It should be noted thatthe terms reinforcing bars, reinforcing rods and reinforcing members maybe utilized interchangeably.

For a product to perform in a manner acceptable for this application, agiven amount of surface deformation must be created during themanufacturing process. It is vital that this deformation creates enoughmechanical bond with a cementitious material without increasing theshear in the fiber beyond an unacceptable yield point as the force isapplied.

The carbon fiber based reinforcing bar may be composed from a pluralityof carbon fibers which are wound or twisted and then set in a resin. Forexample, in one embodiment, three strands of approximately 50,000 carbonfibers each are twisted together and then set (or thermoset) in a resin.The twist forms the deformations or deformation pattern that providesthe friction between the rebar and the material in which the rebar isset. In one embodiment, the number of twists per a given length of thecarbon fibers is predetermined and determined as a function of thenumber and size of fibers and/or strands of fibers.

In one aspect of the present invention, each strand of carbon fibers maybe composed from a tow of carbon fiber filaments. Each tow of carbonfiber filaments has an approximate predetermined number of carbon fiberfilaments. Typical, tows may have 20,000; 30,000; 40,000, 50,000 orother approximate number of filaments. In general, the criticalparameter is the overall strength of the resulting reinforcing bar, rodor member. The size of each filament and the number of filaments indifferent tows may differ. Therefore, based on the size of thefilaments, the (approximate) number of filaments in each tow and thedesired strength of the resulting member, rod or bar, the number ofstrands may be determined. It should be further noted that in someembodiments, a single tow may be used. In these embodiments, the singletow may be considered as including two or more strands. The two or morestrands in the single two are twisted to create the non-uniform surface(see below).

With reference to FIG. 1A, the relationship between the number of twists(angle A) and the shear and tension loads is shown. From the diagram, itis clear that as the angle A increases due to increasing the number oftwists per length of the fibers/strands, the shear load will increase aswell [Shear=Tension(tan(A))]. Because the ultimate shear strength of acarbon fiber is considerably less than the ultimate tensile strength,the transfer of tensile load into shear load will become a limitingfactor in the ultimate failure strength of the material. FIG. 1Aillustrates the transfer of tensile load into shear load. This can bedescribed as Measured Load*(sin(A)). It should also be noted that thetension in the fibers at this location is described as MeasuredLoad*(COS(A)).

With reference to FIG. 1B, there is a range in the number of twists perlinear foot of carbon fiber wherein both the bond strength and theeffective tensile strength are acceptable. It is within this range oftwists per foot that all carbon fiber must embody in order to provideadequate mechanical bond, yet efficiently carry tensile load withoutinducing detrimental shear loads.

In general, the carbon fiber based reinforcing bar (rebar) is formed bypulling carbon fibers (under tension) through a resin bath andsimultaneously, or shortly thereafter, twisting the fibers. The resinimpregnated twisted carbon fibers are then left under tension while theresin cures.

With reference to FIGS. 1C, 1D, 1E, 1F and 1G, an apparatus 10 used inthe formation of the carbon fiber based rebar, according to anembodiment of the present invention, is shown. The apparatus 10 includesa bath housing 12 (which is shown in cross-section in FIGS. 1C and 1D).The bath housing 12 forms a reservoir 14. In use, the reservoir 14 isfilled with (uncured) resin.

As shown, the apparatus 10 includes at least one incoming roller 16, aseries of bottom rollers 18 and a pair of outgoing rollers 20. As shownby the arrows, aligned carbon fibers enter the apparatus 10 (from theleft in FIG. 1C) and are directed over the incoming roller 16. Thefibers are then directed towards (into the resin bath) and around thebottom rollers 18. As the fibers leave the resin bath, the fibers arepulled through the outgoing rollers 20.

In one embodiment, the carbon fibers are in the form of a strand of aplurality of carbon fibers. In a specific embodiment, three strands of50,000 carbon fibers each are used.

The three strands are pulled (or pultruded) through the resin bathsimultaneously and after the fibers leave the resin bath, are twistedtogether. A more specific system and method is described below.

First, the (dry) carbon fiber is pultruded through a series of rollers16, 18, 20 under a constant tension in a resin bath in order to ensurecomplete impregnation of the resin through all fiber strands. After allof the fibers are saturated with resin, they are pultruded through asingle slot 22 (which may be located in a block mounted adjacent thebath housing 12) to remove excess resin (see FIG. 1E). This step alsoensures all of the fibers are aligned and that the cross-sectional areaof the strand is within the acceptable range for the given (or intended)application. This step also ensures that the ratio of CF to epoxy isappropriate. The fibers are then left under a tension load which keepsall fibers aligned during curing. Generally, the block (shown in FIG.1D) will include a slot for each strand of fibers.

At this point, one end of the strand is fixed while the other end istwisted a predetermined number of times until it is within the range oftwists per linear foot required for the intended application. After thetwisting process is complete, both ends of the fiber are fixed and thestrand is cured while remaining under tension. In one aspect of thepresent invention, the predetermined number of twists is determined as afunction of the number and size of the carbon fibers and/or number andsize of the strands of carbon fibers. In another aspect of the presentinvention, the predetermined number of twists may be determined asfunctions of the shear load required of the reinforcing rod, bar ormember.

The process of twisting this strand a pre-specified number of timesresults in a consistently non-uniform surface on the strand, whichgreatly increases the bond strength between the strand and acementitious material. Without this added non-uniformity, the strandwould possess little or no mechanical bond strength with cementitiousmaterials. This is vital as the chemical bond between cement and thetypes of resin used is effectively non-existent.

The strand is allowed to cure per resin manufacturer's suggestion, atwhich time it is ready to be used in production. Again, it is importantto note that the strand remains under load during the curing process andthat the twists are applied to the strand before the curing processbegins.

Another important factor in the manufacture of carbon fiber strands ispredictability of performance. It is vital that the production processproduces a strand that has consistent properties in both bond strengthand ultimate tensile strength. The design values used for both of thesefactors should reflect the distribution of tested data points. That isto say that the design value should not be greater than the lower boundof the first standard deviation of the data set.

After the resin impregnated carbon fiber based rebar has been cured, therebar is ready to be used. In one aspect of the present invention, thecarbon fiber based rebar may be brought under tension and a cementstructure is formed around the pre-stressed fiber based rebar. Once theconcrete has cured, the tension force from the rebar may be released.

With reference to FIGS. 2A-16, a system 50 for pre-stressing areinforcing member within a pre-cast structure is shown. The system 50is particularly useful in pre-stressing a fiber base reinforcing member,such as a carbon fiber based rebar. A carbon fiber based rebar asdetailed above with respect to FIGS. 1A-1D may be used. However, itshould be noted that the system 50 may be used with any fiber basedreinforcing bar.

In general, the system 50 includes three main components: a grippingdevice 52, a tension device 54 and a tension application sub-system 56(A & B).

With particular reference to FIGS. 10-14, the gripping device 52 is usedto provide an attachment to each end of a reinforcing member (or rebar)58. In the illustrated embodiment, the gripping device 52 includes agripping tube 60, such as a steel tube 60. The gripping tube 60 has acalculated length, outer diameter and inner diameter. The parameters ofthe gripping tube 60 are determined to provide enough friction forcebetween the gripping tube 60 and the reinforcing member 58 given thetension force that needs to be applied while the pre-cast structure isbeing cast (see below).

The gripping tube 60 is then filled with an expansive grout 57. A cap 62(see FIGS. 13 and 14) with a pre-drilled hole in the center to guide thereinforcing member 58 is then placed on the gripping tube 60. Cap 62 ismulti-functional in that it contains the expansive grout 57 as well asensures that reinforcing member 58 is concentric with gripping tube 60.The reinforcing member 58 is then inserted through the cap 62 and intothe grout 57. Upon curing, the expansive grout 57 creates a bond on boththe reinforcing member 58 and the inside of the gripping tube 60. Thisbond becomes a friction force upon the application of tension to thegripping tube 60 (one on each end of the reinforcing member 58) by thesystem 50. The friction force is a function of the gripping tube 60,e.g., the length and diameter(s) of the gripping tube 60, as well as thegrout 57. The gripping tube 60 is designed such that the friction forcehas a an ultimate strength greater than the tension force applied to thestructure allowing the gripping tube 60 to be used as an attachmentpoint for the tensioning process. It is important to note that the outerdiameter of the grout tube is also limited by the designed distancebetween the reinforcing members 58. The outer diameter of the tubes 60must be smaller than the centerline distance between the reinforcingstrands to ensure that the tubes 60 for each member 58 do not inhibitone another. The same principal applies to the next part in the tensionsystem 50, as well.

With particular reference to FIGS. 3-9, in the illustrated embodiment,the tension device 54 includes a tension tube 64, allows the tensionapplication sub-system 56 to quickly and easily be attached to thegripping device 52. The tension tube 64, which may also be made ofsteel, has a specified length, outer and inner diameter such that thegripping tube 60 fits inside. The size of the tension tube 64 isdetermined such that the outer diameter of the gripping tube 60 issmaller than the inner diameter of the tension tube 64. The outerdiameter of the tension tube 64 is also limited by the designed distancebetween the reinforcing members 58 (see above). That is, the outerdiameter must be smaller than the centerline distance between thereinforcing members 58 to ensure that the gripping tubes 60 and tensiontubes 64 for each strand do not inhibit one another. If this dimensionwere to become a limiting factor in the design of the reinforcingelement location another tension application system would have to bedesigned to accommodate.

With particular reference in FIGS. 3-9, an insert slot 66 is machinedout of the top of the tension tube 64. The insert slot 66 allows thegripping tube 60 to be inserted quickly without compromising strengthand reducing the amount of time necessary to remove the tension tub andreinstall the next new tension tube for reinforcement bar tensioning. Asmaller slot 68 allows the member 58 to also be inserted into thetension tube 64. One end of the tension tube 64 is (at least partially)closed (see FIG. 9) and includes the smaller slot 68 that allows thereinforcing strand to extend there-through when the grout tube isinserted into the tension tube. The opposite end to the tension tube 64may be threaded (not shown) to allow the attachment of a threaded rod(see below) which connects tension device 54 to be connected to thetension application sub-system 56. A tension tube 64 may be used at bothends of each reinforcing member 58 such that tension can be adjusted ateither end.

With reference to FIGS. 2A-2B and 17-24, the tension applicationsub-system 56 includes a first tension application apparatus 56A and asecond tension application apparatus 56B, one at each end of the members58. While only one tension application apparatus 56A, 56B is shown, theother apparatus 56A, 56B is identical. As will be explained in moredetail below, the tension within the members 58 may be adjusted ateither end through the respective tension application apparatus 56A,56B. It should be noted that in the top down diagrams of FIGS. 2A and2B, two members 58 are shown. However, in the illustrated embodiment,four members 58 are used.

Returning to FIGS. 2A-2B and 17-24, in the illustrated embodiment, eachtension application apparatus 56A, 56B includes first and secondassembly brackets 70A, 70B. The first and second removable brackets 70A,70B, each include a base 70 with a plurality of through holes 76. Thetension application apparatus 56A, 56B may be mounted, e.g., bolted, toa surface (see for example, FIGS. 24A, 24B and 24C) via the throughholes 76.

The first and second assembly brackets 70A, 70B may be fixed togetherusing bolts (not shown) through alignment holes 74 in respective uprightcorner walls 72A-1, 72A-2, 72B-1, 72B-2. An interchangeable, removableplate 78 is provided between the first and second assembly brackets 70A,70B.

For each gripping device 52/tension device 54 pair, a coupling mechanism80 is provided. The coupling mechanism 80 couples the respectivegripping device 52/tension device 54 pair to the tension applicationapparatus 56A, 56B.

In the illustrated embodiment, the coupling mechanism 80 includes afirst threaded rod 82. A first end of the first threaded rod 82 isthreaded into a threaded aperture in the opposite end of the tensiontube 64 of the tension device 54 (or otherwise coupled thereto). Theopposite end of the first threaded rod 82 is threaded into one end of arespective load cell 84 (or otherwise coupled thereto). A secondthreaded rod 86 is threaded into a second end of the respective loadcell 84. The opposite end of the second threaded rod 86 is insertedthrough a respective hole in the plate 78. An adjustment nut 88 isthreaded onto the opposite end of the second threaded rod 86. Rotationof the adjustment nut 88 controls the tension or force applied to therespective member 58. The tension imposed on the members 58 causes adeflection (in either direction) within the respective load cell 84which may be measured.

In use, once both ends of the tension application sub-system 56 arefixed, torque is applied to this adjustment nut 88, resulting in atension load being created in the reinforcing member(s) 58. The assemblybrackets 70A, 70B hold the plate 78 in place and are securely fastenedto a true and secure surface with adequate structural capacities. Theassembly brackets 70A, 70B are coplanar to ensure that the reinforcingmembers 58 under tension are level. An integral portion of the bulk headis the plate through which the threaded rods are inserted and theadjustment nut(s) 88 tightened against. The bulk head is designed suchthat this plate 78 is removable for quick and easy alteration of thereinforcing strand locations.

In the illustrated embodiment, the pre-cast structure is formed using aform shape or mold 90. The members 58 extend from the first tensionapplication apparatus 56A, through the form 90, to the second tensionapplication apparatus 56B.

The first step is to place all reinforcing members 58 required for thepre-cast structure into the form 90 with the gripping tubes 60 in therespective tension tubes 64. Tension is then applied to the system viathe adjustment nuts 88 and set to the proper torque to yield the correctvalue in tension. The cementitious material may be then poured into theform 90, around the reinforcing members 58. Tension is again verifiedbefore the cementitious material is left to cure. After the material iscured to the proper strength, the tension is systematically released atan equal rate among all reinforcing members 58. At this point, thegripping tubes 60 may be cut off (and disposed of) and the member isremoved from the form 90. The forms 90 can be cleaned and the system 50prepared to begin the process over again.

The dimensions chosen for the prototype concrete member were governed bythe dimensional, and load bearing requirements of the chosenconstruction system, the ACI cover depth requirements for reinforcingmembers 58, and load capacity of reinforcing members 58. The ACIrequires a minimum cover depth based on reinforcing member material andcorrosive properties. That is to say there is a minimum distance fromthe surface of the concrete member to the closest surface of thereinforcing element. It is important to note that the cover depth for acomposite fiber reinforcing element is less than that of a steelreinforcing element due to the difference in corrosive properties. Thisrequirement shows that a member reinforced with a composite elementcould have a thinner cross sectional area than one reinforced withsteel. For example the minimum cover depth for a steel member is 0.75″,therefore a member with a single 0.25″ reinforcing element could only be1.75″ thick at the minimum. Whereas a composite member requires 0.375″of cover therefore the same size reinforcing element could yield amember 1″ thick. It was this principal along with the engineered loadrating for the member that would govern the dimensions chosen for theprototype composite reinforced, precast, pre-stressed concrete member.

Method to Attach Block, to a Precast/Pre-Stressed Concrete Member

In some applications, it is desirable to attach a different type ofmaterial, e.g., wood, to a precast concrete structure. For example, itmay be desirable to use the precast cement structure as a girt on gradeor “splashboard” in a post frame construction system. In such systems,different building parts must be attached to the precast concretestructure. In one aspect of the present invention, this method shouldincrease versatility and facilitate quicker installation of fastenerparts for optimal onsite field construction efficiency.

In one aspect of the present invention, a first attachment part 91A anda second attachment part 91B may be embedded in a pre-stressed, pre-caststructure. The first attachment part 91A has a first body 93A. The firstbody 93A has a first concrete structure facing side 95A and a firstplurality of attachment members 97A extending from the concretestructure facing side 95A. The second attachment part 91B has a secondbody 93B. The second body 93B has a second concrete structure facingside 95B and a second plurality of attachment members 97B extending fromthe concrete structure facing side 95B (see below). The first and secondattachment parts 91A, 91B may be spaced apart forming a compressiblejunction 99 therebetween. The pre-cast, pre-stressed concrete structureis formed from uncured cement. At least of a portion of the first andsecond attachment members 97A 97B are embedded in the pre-cast,pre-stressed concrete structure. As discussed below, the first andsecond attachment parts 91A, 91B may be composed of wood, lumber,plastic, metal or a composite material.

With reference to FIGS. 25-27C, a system 100 includes one or moreattachment parts or blocks, e.g., pieces of wood or lumber, beingintegrated with the precast cement structure. Concrete is a materialthat requires pre-drilling, so it may require additional work to attachpieces, building components to the cement structure. The use of anattachment part or block allows for the easy and efficient installationof building components, for example, ribbed steel panels. The panels maybe bolted or otherwise fastened to the integrated piece of lumber.

With particular reference to FIG. 25, an exemplary block, e.g., piece oflumber, 102 is shown that may be integrated with the precast cementstructure during the casting process (see above). As shown, the block102 includes a number of shear studs 104 embedded therein. In theillustrated embodiment, an even number of shear studs 104 are provided:one half of the shear studs 104 on one side of the center of the block102 and one half of the shear studs 104 on the other side of the centerof the block 102. In other embodiments, see for examples, FIGS. 26A-27C,an odd number of shear studs 104 may be provided.

However, casting a block 102 with shear studs 104 into a pretensionedconcrete structure poses new problems that must be addressed in order tomaintain a geometrically sound and acceptable member.

The shear studs 104 may be cast into the concrete member during thepouring process. As discussed above, the applied tension on the rebar isreleased after the cement is cured. When the tension is released in thecured, pre-tensioned, precast concrete structure, a compression force(see FIG. 25) is transferred causing the structure to decrease in lengthin an incremental amount varying by the tension applied, thecross-sectional area of the member, and its composition.

This poses a problem for any material that is cast into thepre-tensioned, precast concrete structure as the item cast into thestructure must have the ability to be slightly compressed at a ratesimilar to the concrete structure. If the item cast into the concretemember has dissimilar elastic properties or unsymmetrical geometricproperties, the resulting internal stresses can yield unacceptabledeflection (see FIG. 28).

With reference to FIG. 29, in one aspect of the present invention, thisissue may be solved by creating a relief cut in the block 102 or providea plurality of blocks 102 with a relief or space. The relief may befilled with a compressible material 108 casting the pre-cast concretestructure 106. This “compressible void” acts as a cushion for the blocks102 to compress along with the precast concrete structure 106.

Even with the “compressible void”, a certain amount of moment is appliedto the block(s) 102 due to the shear transfer facilitated by the shearstuds 104 and the fact that they are a distance away from the centerlineof the blocks 102 (see FIG. 25). While this moment is a function of thecompression force, the size of the blocks 102, and the frequency ofshear studs 104, the stress and deflection in the block 102 is afunction of its moment of inertia and the moment caused by thecompression. As the moment of inertia is related to the cross-sectionalarea and length, the relationship is such that with all other variablesequal, a block 102 with less length will yield less deflection. Thisrelationship may be used to determine the optimal distance between“compressible voids” for each value of pretension force. This inverserelationship is such that higher pretension values require smallerdistance between “compressible voids”.

In one aspect of the present invention, a method is provided. Stress isapplied to a reinforcing member. The first and second attachment partsare positioned at predetermined positions relative to the reinforcingmember. The first attachment part has a first body. The first body has afirst concrete structure facing side and a first plurality of attachmentmembers extending from the concrete structure facing side. The secondattachment part has a second body. The second body has a second concretestructure facing side and a second plurality of attachment membersextending from the concrete structure facing side. The first and secondattachment parts are spaced apart forming a compressible junction. Aconcrete form is positioned at a predetermined location about thereinforcing member and the first and second plurality of attachmentmembers. Uncured cement is poured in the concrete form. The uncuredcement encases at least partially, the reinforcing member and the firstand second plurality of attachment members. Then, the cement is allowedto cure and the stress is released from the reinforcing member.

It should be noted that the steps of this method do not necessarily needto be performed in the order listed above. For example, the step ofpositioning the first and attachment parts at predetermined positionsrelative to the reinforcing member may be performed before or after theuncured cement is poured into the form.

In another aspect of the present invention, a method to attach the blockor lumber 102 to the precast concrete structure 106 is provided. Asconcrete does not chemically bond with wood, a system 100 of mechanicalanchoring is required. In the illustrated embodiment, a series of shearstuds 104 is placed in the lumber or block 102. A portion of the lengthof each shear stud 104 remains exposed. The cementitious material isthen cast around the shear studs 104, thereby bonding the lumber to theprecast concrete structure 106. The spacing of the shear studs 104 iscritical and varies depending on the amount of load that is required tobe transferred from the block(s) 102 into the precast concrete structure106. The frequency of the shear studs 104 may be increased beyond theminimum requirement to allow the cement structure(s) to be cut in anylocation while maintaining adequate shear transfer.

The method of applying shear studs 104 to the underside of a block orwooden member 102 before the member is cast in cementitious material isshown in FIGS. 26A-27C. In the illustrated embodiment, the spacingbetween studs is 4″ though this is subject to change with correspondingstructural loads to be transferred into the precast concrete structure106. The size of the lumber block 102 depicted is a 1.5″ crosssectional-square though this is also subject to change dependent on theapplication.

It is important to note that the shear studs 104 in the block 102 shouldbe placed such that the shear studs 104 do not interfere with anyreinforcing elements that may be within the cementitious material. It isalso important to note that the shape of the wooden block is notrestricted to square. Any shape that suits a particular application aslong as there is a flat base for the installation of the shear studs 104will be acceptable. The shear studs 104 should be comprised of acorrosion resistant material. For example, FIGS. 26A-26C illustrate ablock 102 having a square cross-section. In particular, the block 102 iscomposed of a 1.5″-1.5′ treated lumber block 102 having a maximum lengthof 24″. The shear studs 104 are corrosive resistant fasteners having a4″ spacing. In FIGS. 27A-27C, the block 102 has a groove (as shown) thatmay be useful for fastening building components thereto.

The spacing of the “relief cuts” and resulting “compressible void” issubject to change in pretensioned elements under differing loads.

Method to Attach Metal Plate or Fin to a Precast/Pre-Stressed ConcreteMember

In an alternative embodiment, the first and second attachment parts maybe made from metal. For example, an integral piece of galvanized steelor metal plate 200 may include with the concrete structure to facilitatean easy installation of building components. However, casting a sectionof galvanized steel 200 (FIG. 30A) into a pretensioned concretestructure poses new problems that must be addressed in order maintain astructurally sound member.

With reference to FIGS. 30A and 30B, a system 200 includes one or moremetal plates 204 that are integrated with the precast, pre-stressedconcrete structure 210. This allows for the easy and efficientinstallation of building components, for example, ribbed steel panels.

In one aspect of the present invention, the system 200 includes aplurality of plates 204. In the illustrated embodiment, each plate 204includes an upright member 205 to which building components may befastened. Each plate 204 also includes a slot and groove mechanism 206that provides a slip joint between adjacent plates 204. The slot andgroove mechanism 206 includes a tab 206B and a plurality of offsethorizontal members 206A which are offset to form a slot for receiving atab 206B from an adjacent plate 204. Each plate 204 also includes aplurality of fins 208. The fins 208 are embedded in the uncured cementthat forms the precast, pre-stressed cement structure 210. In theillustrated embodiment half of the fins 208A, are deflected from theupright member 205 at a predetermined angle. The other half of the fins208B are deflected from the upright member 205 at an opposite angle.Further, in the illustrated embodiment each fin 208 has a hole.

When the tension is released in the cured, pretensioned, precastconcrete structure 210, the concrete structure 210 will decrease inlength in an incremental amount varying by the tension applied and thecross-sectional area of the structure 210. This poses a problem for anymaterial that is cast into the pretensioned, precast concrete structure210 as the item cast into the item must have the ability to be slightlycompressed. If the item cast into the precast concrete structure 210,and the member is not compressible at a rate similar to the concretestructure 210 then the resulting internal stresses can causeunacceptable deflection of the entire member.

This issue is addressed in several ways. The first method involvescreating a slip joint between sections of metal plates 200. This allowssmaller pieces of galvanized metal to be used and allows them to “slip”a small amount at the joints where the two pieces meet. The secondmethod for solving this issue involves leaving a gap between the piecesof galvanized metal fin and filling said gap with a compressiblematerial. This “compressible void” allows the metal plates 200 to movecloser together (or further apart) as tension is released thus relievinga portion of the internal stress in the material yielding a finishedproduct that is suitable for the intended use.

The same principal used to describe the moment to length relationship ofblock(s) 102 in section [0044] can also be applied to plates 200. Thatis to say that there is a moment applied upon plates 200 as theircontact with the compression force is a distance away from thecenterline of plates 200. While this moment is a function of thegeometry of tabs 208, the compression force of the reinforcing elementsand the cross sectional geometry of the plate 200, the stress anddeflection of said plate is a function of its moment of inertia and themoment induced by the compression. As the moment of inertia is relatedto the cross sectional area and the length, it could be shown that ifall other variables were equal, a plate 200 of a shorter length wouldyield less deflection. This relationship along with the determination ofan acceptable deflection range may be used to find the optimal length ofthe plate 200 as well as optimal dimensions for the “compressible voids”or “slip joints.” This same relationship could also be used to show thata higher pre-tensioning load would require a decrease in the length ofplate 200 in order to keep deflection within said acceptable range.

The second problem comes with developing a method to attach thegalvanized steel or “plate 200” to the precast member. While thegalvanized steel will chemically bond to the cementitious material to acertain extent, a level of mechanical bonding is required. This is oftenachieved by creating a surface on the material that is non-uniform. Anon-uniform surface will create small shear faces in the cementitiousmaterial along the length of the bonding surface. In the case of thegalvanized steel fin 208A, 208B, this can be achieved by altering thesurface geometry of the part. Both putting holes in the fins 208A, 208Band putting bends in the part will each sufficiently increase the bondstrength of the galvanized steel and the concrete to a level that isacceptable for this application.

It is important to note that fins 208 or plate 200 is made from acorrosive resistant material or may be coated with a corrosive resistantsubstance or protection layer. Whenever a steel sample is cast within aconcrete member there is the potential that the steel will deteriorateover time causing the concrete sample to crack, spall and eventuallyfail. This is caused in part by chloride ions within the concrete samplethat break down the protective layer around the steel that is createdduring the early stages in the concrete curing process. Once thisprotective layer is gone, there is opening for oxidation of the ironions within the steel which yields iron oxide or what we refer to asrust. The process of galvanization adds a protective layer of zinc overthe entire steel part. Once within the concrete this protective zinccoating propagates out, creating an even broader barrier against thechloride ions and oxidation.

In another aspect of the present invention, a method of producing agalvanized metal plate 200 that can be cast into a pretensioned, precastconcrete member and that facilitates the attachment of said structure toother building components is provided. The galvanized plate 200 is of analtered cross sectional geometry such that the shape adds an increasedlevel of mechanical bonding with the cementitious material it is castinto. The galvanized plate 200 is of a specified length which is variedin relation to the application and pretensioning loads used in givenmember. The relationship is such that a higher pretension load willrequire a shorter maximum length plate 200. The ends of each plate 200are shaped in such a manner that they fit together as a “slot and tab”mechanism. This allows the plate 200 and cementitious member 210 to movelinearly with respect to one another without moving in the sheardirection.

Method to Attach a Nailable Substrate to a Precast/Prestressed ConcreteMember

In order to employ a precast concrete member 106 as a splashboard in aconstruction system, a method of attachment for all building parts mustbe developed. This method should increase versatility and facilitatequicker installation of fastener parts for optimal connectionefficiency. It was determined that an integral nailable substrate couldbe included with the concrete member to facilitate an easy installationof, e.g., steel panels or exterior sheathing along with thecorresponding trims and accessories. Casting a section of a nailablematerial with attachment members 97A, 97B (see above), such as shearstuds, into a pre-tensioned concrete member poses new problems that mustbe addressed in order to maintain a geometrically sound and acceptablemember. When the tension is released in a cured, pre-tensioned, precastconcrete member, a compression force is transferred causing said memberto decrease in length in an incremental amount varying by the tensionapplied, the cross sectional area of the member, its composition, andresulting modulus of elasticity.

This poses a problem for any material that is cast into a pre-tensioned,precast concrete member as the item cast into the member must have theability to be slightly compressed at a rate similar to the concretemember. If the item cast into the concrete member has dissimilar elasticproperties such that the center of the pre-stress load is not concentricwith the center of rigidity of the combined member, the resultinginternal stresses can yield unacceptable deflection.

The relationship between tension force, modulus of elasticity andoverall length change of the member is such that a higher force with andequal Young's Modulus will yield a larger decrease in length.Furthermore, if the tension force is equal and the modulus of oneportion of the member is lower than another portion of the member, thesection with a lower modulus will decrease in length by a greateramount. If we combine these two ideas it could be stated that if amember has a large variance in Young's Modulus, the tension force couldbe varied through the plurality of reinforcing elements such that theoverall decrease in length of the member would be consistent throughout.

A method to attach the nailable substrate to the precast concrete isprovided. As concrete will not chemically bond with many nailablematerials, a system of mechanical anchoring is required. It was foundthat a series of attachment members, e.g., shear studs, could be placed(attached, screwed, nailed, driven, etc. . . . ) in the nailablesubstrate with a portion of the length of said stud remaining exposed.The cementitious material is then cast around these studs bonding thenailable member to the cast concrete member. The spacing of these studsis critical and varies depending on the amount of load that is requiredto be transferred from the nailable substrate into the precast concretemember. Frequency of studs is increased beyond the minimum requirementto allow members to be cut in any location while maintaining adequateshear transfer.

The method of applying studs to a face perpendicular to the intendednailing face of a nailable member before said member is cast incementitious material is illustrated in FIG. 31. The spacing betweenstuds in this figure is 4″ though this is subject to change withcorresponding structural loads to be transferred into the concretemember. The size of the nailable member is a standard nominal “2×4”though this is also subject to change dependent on the application.

It is important to note that the studs in the nailable member should beplaced such that they do not interfere with any reinforcing elementsthat may be within the cementitious material. It is also important tonote that the shape of the nailable member is not restricted. Any shapethat suits a particular application as long as there is a flat base forthe installation of the studs will be acceptable. The shear studs usedshould be comprised of a corrosion resistant material.

As is shown in FIG. 31 and described herein, if Modulus 1 issignificantly less than Modulus two, a higher tension load can be placedon the lower of the two reinforcing elements 302A, 302B shown in orderto equalize the decrease in length across the entire member thuseliminating the change of deflection from these internal stresses. Theamount that the tension is varied between the reinforcing elements 302A,302B is dependent on the difference in the Modulus's in the member aswell as the reinforcing element locations in relationship to thecentroid of the member. The cross sectional area of each element 302A,302B that comprises the member will also affect the required tensionvariation. It should be noted that a concrete member may have more thantwo such elements. If such member has more than two reinforcingelements, the tension load can be varied among them in a “stepped”fashion in order to meet the requirements of the member. It should benoted that reinforcing elements may be suitable reinforcing member, bar,rod, including the reinforcing members, bars, or rods disclosed herein,or any other suitable reinforcing member.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Other aspects and features ofthe present invention can be obtained from a study of the drawings, thedisclosure, and the appended claims. The invention may be practicedotherwise than as specifically described within the scope of theappended claims. It should also be noted, that the steps and/orfunctions listed within the appended claims, notwithstanding the orderof which steps and/or functions are listed therein, are not limited toany specific order of operation.

Although specific features of various embodiments of the invention maybe shown in some drawings and not in others, this is for convenienceonly. In accordance with the principles of the invention, any feature ofa drawing may be referenced and/or claimed in combination with anyfeature of any other drawing.

What is claimed is:
 1. A reinforcing bar, comprising: a plurality ofstrands, each strand including a plurality of carbon fibers, the strandshaving been impregnated with a resin and twisted forming a unifiedstructure; and, a deformity pattern within the unified structure formedby twisting the strands a predetermined number of times per linear footof the unified structure and allowing the resin-impregnated unifiedstructure to cure.
 2. A reinforcing bar, as set forth in claim 1,wherein the predetermined number of twists is determined as a functionof the number and size of the carbon fibers and/or strands of carbonfibers.
 3. A reinforcing bar, as set forth in claim 2, wherein thepredetermined number of twists is further determined as a function of arequired shear load.
 4. A reinforcing bar, as set forth in claim 1,wherein the plurality of strands includes at least three strands ofcarbon fibers.
 5. A reinforcing bar, as set forth in claim 1, whereineach strand of carbon fibers is composed of a tow of carbon fiberfilaments, each tow having an approximate predetermined number of carbonfiber filaments.
 6. A reinforcing bar, as set forth in claim 1, whereinthe reinforcing bar has an outer surface and the deformity patterncreates a consistent non-uniform pattern on the surface of thereinforcing bar.
 7. A concrete structure, comprising: a concrete member;and, a reinforcing bar, the concrete member being formed about thereinforcing bar while the reinforcing bar is under stress, thereinforcing bar including a plurality of strands, each strand includinga plurality of carbon fibers, the strands having been impregnated with aresin and twisted forming a unified structure, and a deformity patternwithin the unified structure formed by twisting the strands apredetermined number of times per linear foot of the unified structureand allowing the resin-impregnated unified structure to cure.
 8. Aconcrete structure, as set forth in claim 7, wherein the predeterminednumber of twists is determined as a function of the number and size ofthe carbon fibers and/or strands of carbon fibers.
 9. A concretestructure, as set forth in claim 8, wherein the predetermined number oftwists is further determined as a function of a required shear load. 10.A concrete structure, as set forth in claim 7, wherein the plurality ofstrands includes at least three strands of carbon fibers.
 11. A concretestructure, as set forth in claim 7, wherein each strand of carbon fibersis composed of a tow of carbon fiber filaments, each tow having anapproximate predetermined number of carbon fiber filaments.
 12. Aconcrete structure, as set forth in claim 1, wherein the reinforcing barhas an outer surface and the deformity pattern creates a consistentnon-uniform pattern on the surface of the reinforcing bar.
 13. A method,including the steps of: dipping a plurality of strands of carbon fibersin a bath of resin, wherein the fibers in each strand are aligned;pulling the strands of carbon fibers through an outgoing pair ofrollers, as the strands leave the bath of resin; twisting the strands ofcarbon fibers together to form a desired deformity pattern; and,allowing the resin to cure to form a reinforcing bar.
 14. A method, asset forth in claim 13, wherein the step of dipping the plurality ofstrands of carbon fibers in a bath of resin is performed using a bathstructure having a housing, at least one incoming roller, a series ofbottom rollers, and a pair of outgoing rollers, the housing forming areservoir containing uncured resin, the series of bottom rollers beinglocated at a bottom of the reservoir, wherein the step of dipping theplurality of strands in a bath of resin, includes the steps of: pullingthe strands of carbon fibers, under tension, over the at least oneincoming rollers; pulling the strands alternatively over and under, theseries of bottom rollers; and, pulling the strands through the pair ofoutgoing rollers.
 15. A method, as set forth in claim 13, wherein, thestrands of carbon fibers, upon leaving the resin bath are pulled througha slot.
 16. A method, as set forth in claim 13, wherein the steps oftwisting the strands of carbon fibers together and allowing the resin tocure are performed while the strands of carbon fibers are under tension.17. A method, as set forth in claim 13, including the following stepsafter the resin has cured: applying stress to the reinforcing bar;forming a concrete structure about the reinforcing bar; and, releasingthe stress applied to the reinforcing bar after the concrete has cured.18. A method, as set forth in claim 13, wherein the strands of carbonfibers are twisted a predetermined number of times, the number of timesthe carbon fibers are twisted is determined as a function of the numberand size of the carbon fibers and/or strands of carbon fibers.
 19. Amethod, as set forth in claim 18, wherein the predetermined number oftwists is further determined as a function of a required shear load ofthe reinforcing bar.
 20. A method, as set forth in claim 18, wherein theplurality of strands includes at least three strands of carbon fibers.21. A method, as set forth in claim 18, wherein each strand of carbonfibers is composed of a tow of carbon fiber filaments, each tow havingan approximate predetermined number of carbon fiber filaments.
 22. Areinforcing bar, as set forth in claim 13, wherein the reinforcing barhas an outer surface, wherein the step of twisting the strands of carbonfiber together creates a deformity pattern in the outer surface having aconsistent non-uniform pattern.